Flexible Container with Fitment

ABSTRACT

The present disclosure provides a flexible container. In an embodiment, the flexible container includes (A) four panels, each panel comprising a flexible multilayer film. The flexible multilayer film includes a polymeric material composed of a polymeric material. The four panels form (i) a body, and (ii) a neck. The flexible container includes (B) a fitment having a top portion and a base. The fitment is composed of a polymeric material. The base is sealed in the neck. The base has (C) a cross-sectional shape with a diameter (d), and the base has a wall thickness (WT). The base has a d/WT ratio wherein the d/WT ratio (in mm) is from 35 to 800.

BACKGROUND

The present disclosure is directed to a flexible container with adispensing fitment and a standup flexible container with a dispensingfitment in particular.

Flexible packaging is known to offer significant value andsustainability benefits to product manufacturers, retailers andconsumers as compared to solid, molded plastic packaging containers.Flexible packaging provides many consumer conveniences and benefits,including extended shelf life, easy storage, microwavability andrefillability. Flexible packaging has proven to require less energy forcreation and creates fewer emissions during disposal.

Flexible packaging includes flexible containers with a gusseted bodysection. These gusseted flexible containers are currently produced usingflexible films which are folded to form gussets and heat sealed in aperimeter shape. The gusseted body section opens to form a flexiblecontainer with a square cross section or a rectangular cross section.The gussets are terminated at the bottom of the container to form asubstantially flat base, providing stability when the container ispartially or wholly filled. The gussets are also terminated at the topof the container to form an open neck for receiving a rigid fitment andclosure.

Conventional procedures for fabricating gusseted flexible containerswith a rigid fitment have shortcomings. The fitment requires a materialand a thickness strong enough to withstand the heat and compressionforce imparted by opposing seal bars during the sealing process. Thisrequirement constrains the diameter of the fitment base. The fitmentmaterial must also be compatible with the container film material inorder to form a heat seal weld.

Fitments with a canoe-shaped base or a base with extended radial finsoriented 180° apart, are not practical for flexible containers with morethan two panels because the base geometry of these fitments does notmatch the geometry of containers with three, four, or more panels.

A need exists for a gusseted flexible container having an enlargedfitment base diameter. A need further exists for a gusseted flexiblecontainer having a thin-wall fitment, alone or in combination with, anenlarged fitment base diameter.

SUMMARY

The present disclosure provides a flexible container. In an embodiment,the flexible container includes (A) four panels, each panel comprising aflexible multilayer film. The flexible multilayer film includes apolymeric material. The four panels form (i) a body and (ii) a neck. Theflexible container includes (B) a fitment having a top portion and abase. The fitment is composed of a polymeric material. The base issealed in the neck. The base has (C) a cross-sectional shape with adiameter (d), and the base has a wall thickness (WT). The base has ad/WT ratio, wherein the d/WT ratio (in mm) is from 35 to 800.

An advantage of the present disclosure is a flexible container withimproved seal strength between the fitment and the flexible containerpanels.

An advantage of the present disclosure is a flexible container with atransparent fitment through which the material being dispensed from theflexible container can be seen.

An advantage of the present disclosure is a flexible container with afitment made with a reduced amount of polymeric material.

An advantage of the present disclosure is a flexible container with athin-wall fitment.

An advantage of the present disclosure is a flexible container with aflexible fitment.

An advantage of the present disclosure is a flexible container with afitment made from a polymeric material having a low modulus.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation view of a flexible container in a collapsedconfiguration in accordance with an embodiment of the presentdisclosure.

FIG. 2 is an exploded side elevation view of a panel sandwich.

FIG. 3 is a perspective view of the flexible container of FIG. 1 in anexpanded configuration and in accordance with an embodiment of thepresent disclosure.

FIG. 4 is a bottom plan view of the expanded flexible container of FIG.3 in accordance with an embodiment of the present disclosure.

FIG. 5 is a top plan view of the flexible container of FIG. 3.

FIG. 6 is an enlarged view of Area 6 of FIG. 1.

FIG. 7 is an elevation view of a fitment in accordance with anembodiment of the present disclosure.

FIG. 8 is a bottom plan view of the fitment taken along line 8-8 of FIG.7.

DETAILED DESCRIPTION

The present disclosure provides a flexible container. In an embodiment,the flexible container includes (A) four panels. Each panel includes aflexible multilayer film. The flexible multilayer film includes apolymeric material. The four panels form (i) a body and (ii) a neck. Theflexible container includes (B) a fitment. The fitment has a top portionand a base. The fitment is composed of a polymeric material. The base issealed in the neck. The base has (C) a cross sectional shape with adiameter (d), and the base has a wall thickness (WT).

1. Flexible Container

The flexible container includes panels, each panel composed of aflexible multilayer film. The flexible container can be made from two,three, four, five, six, or more panels. In an embodiment, the flexiblecontainer 10 has a collapsed configuration (as shown in FIG. 1) and hasan expanded configuration (shown in FIGS. 3, 4, 5). FIG. 1 shows theflexible container 10 having a bottom section I, a body section II, atapered transition section III, and a neck section IV. In the expandedconfiguration, the bottom section I forms a bottom segment 26, as shownin FIG. 4. The body section II forms a body portion. The taperedtransition section III forms a tapered transition portion. The necksection IV forms a neck portion.

In an embodiment, the flexible container 10 is made from four panels, asshown in FIGS. 1-6. During the fabrication process, the panels areformed when one or more webs of film material are sealed together. Whilethe webs may be separate pieces of film material, it will be appreciatedthat any number of the seams between the webs could be “pre-made,” as byfolding one or more of the source webs to create the effect of a seam orseams. For example, if it were desired to fabricate the present flexiblecontainer from two webs instead of four, the bottom, left center, andright center webs could be a single folded web, instead of threeseparate webs. Similarly, one, two, or more webs may be used to produceeach respective panel (i.e., a bag-in-a-bag configuration or a bladderconfiguration).

FIG. 2 shows the relative positions of the four webs as they form fourpanels (in a “one up” configuration) as they pass through thefabrication process. For clarity, the webs are shown as four individualpanels, the panels separated and the heat seals not made. Theconstituent webs form first gusset panel 18, second gusset panel 20,front panel 22 and rear panel 24. The panels 18-24 are a multilayerfilm, as discussed in detail below. The gusset fold lines 60 and 62 areshown in FIGS. 1 and 2.

As shown in FIG. 2, the folded gusset panels 18, 20 are placed betweenthe rear panel 24 and the front panel 22 to form a “panel sandwich.” Thegusset panel 18 opposes the gusset panel 20. The edges of the panels18-24 are configured, or otherwise arranged, to form a common periphery11 as shown in FIG. 1. The flexible multilayer film of each panel web isconfigured so that the heat seal layers face each other. The commonperiphery 11 includes the bottom seal area including the bottom end ofeach panel.

When the flexible container 10 is in the collapsed configuration, theflexible container is in a flattened state, or in an otherwise evacuatedstate. The gusset panels 18, 20 fold inwardly (dotted gusset fold lines60, 62 of FIG. 1) and are sandwiched by the front panel 22 and the rearpanel 24.

FIGS. 3-5 show flexible container 10 in the expanded configuration. Theflexible container 10 has four panels, a front panel 22, a rear panel24, a first gusset panel 18 and a second gusset panel 20. The fourpanels 18, 20, 22, and 24 form the body section II and extend toward atop end 44 and extend toward a bottom end 46 of the container 10.Sections III and IV (respective tapered transition section, necksection) form a top segment 28. Section I (bottom section) forms abottom segment 26.

The four panels 18, 20, 22 and 24 can each be composed of a separate webof film material. The composition and structure for each web of filmmaterial can be the same or different. Alternatively, one web of filmmaterial may also be used to make all four panels and the top and bottomsegments. In a further embodiment, two or more webs can be used to makeeach panel.

In an embodiment, four webs of film material are provided, one web offilm for each respective panel 18, 20, 22, and 24. The process includessealing edges of each film to the adjacent web of film to formperipheral seals 41 and peripheral tapered seals 40 a-40 d (40) (FIGS.1, 3, 4, 5). The peripheral tapered seals 40 a-40 d are located on thebottom segment 26 of the container, as shown in FIG. 4, and have aninner edge 29 a-29 f. The peripheral seals 41 are located on the sideedges of the container 10, as shown in FIG. 3. Consequently, the processincludes forming a closed bottom section I, a closed body section II,and a closed tapered transition section III.

To form the top segment 28 and the bottom segment 26, the four webs offilm converge together at the respective end and are sealed together.For instance, the top segment 28 can be defined by extensions of thepanels sealed together at the tapered transition section III, and theneck section IV. The top end 44 includes four top panels 28 a-28 d (FIG.5) of film that define the top segment 28. The bottom segment 26 can bedefined by extensions of the panels sealed together at the bottomsection I. The bottom segment 26 can also have four bottom panels 26a-26 d of film sealed together and can also be defined by extensions ofthe panels at the opposite end 46, as shown in FIG. 4.

The neck portion can be located at a corner of the body 47, or in one ofthe four panels. In an embodiment, the neck 30 is positioned at amidpoint of the top segment 28. The neck 30 may (or may not) be sizedsmaller than a width of the body section II, such that the neck 30 canhave an area that is less than a total area of the top segment 28. Thelocation of the neck 30 can be anywhere on the top segment 28 of thecontainer 10.

In an embodiment, the neck 30 is formed from two or more panels. In afurther embodiment, the neck 30 is formed from four panels.

In an embodiment, the neck 30 is sized to accommodate a wide-mouthfitment. A “wide-mouth fitment,” is a fitment 70 having a diametergreater than 50 mm.

Although FIGS. 1 and 3 show the flexible container 10 with a top handle12 and a bottom handle 14, it is understood the flexible container 10may be fabricated without handles or with only one handle. When theflexible container 10 has a top handle 12, the neck 30 is locatedcentered on the top segment 28 between the handle bases to facilitateeasy pouring.

The four panels of film that form the flexible container 10 extend fromthe body section II (forming body 47), to the tapered transition sectionIII (forming tapered transition portion 48), to form a neck 30 (in theneck section IV). The four panels of film also extend from the bodysection II to the bottom section I (forming bottom portion 49). When theflexible container 10 is in the collapsed configuration (FIG. 1), theneck 30 has a width, F, that is less than the width of the taperedtransition section III. The neck 30 includes a neck wall 50. FIGS. 1 and3 show the neck wall 50 forms an open end 51 for access into theflexible container interior. The panels are sealed together to form aclosed bottom section I, a closed body section II, and a closed taperedtransition section III. Nonlimiting examples of suitable heatingprocedures include heat sealing and/or ultrasonic sealing. When theflexible container 10 is in the expanded configuration, the open end 51of the neck wall 50 is open or is otherwise unsealed. When the flexiblecontainer 10 is in the collapsed configuration, the open end 51 isunsealed and is openable. The open end 51 permits access to thecontainer interior through the neck wall 50 and the neck 30 as shown inFIGS. 3 and 5.

As shown in FIGS. 1, 3-4, the flexible bottom handle 14 can bepositioned at a bottom end 46 of the container 10 such that the bottomhandle 14 is an extension of the bottom segment 26.

Each panel includes a respective bottom face. FIG. 4 shows fourtriangle-shaped bottom faces 26 a-26 d, each bottom face being anextension of a respective film panel. The bottom faces 26 a-26 d make upthe bottom segment 26. The four panels 26 a-26 d come together at amidpoint of the bottom segment 26. The bottom faces 26 a-26 d are sealedtogether, such as by using a heat-sealing technology, to form the bottomhandle 14. For instance, a weld can be made to form the bottom handle14, and to seal the edges of the bottom segment 26 together. Nonlimitingexamples of suitable heat-sealing technologies include hot bar sealing,hot die sealing, impulse sealing, high frequency sealing, or ultrasonicsealing methods.

FIG. 4 shows bottom segment 26. Each panel 18, 20, 22, 24 has arespective bottom face 26 a-26 d that is present in the bottom segment26. Each bottom face is bordered by two opposing peripheral taperedseals 40 a-40 d. Each peripheral tapered seal 40 a-40 d extends from arespective peripheral seal 41. The peripheral tapered seals for thefront panel 22 and the rear panel 24 have an inner edge 29 a-29 d (FIG.4) and an outer edge 31 (FIG. 6). The peripheral tapered seals 40 a-40 dconverge at a bottom seal area 33 (FIGS. 1, 4, 6).

The front panel bottom face 26 a includes a first line A defined by theinner edge 29 a of the first peripheral tapered seal 40 a and a secondline B defined by the inner edge 29 b of the second peripheral taperedseal 40 b. The first line A intersects the second line B at an apexpoint 35 a in the bottom seal area 33. The front panel bottom face 26 ahas a bottom distalmost inner seal point 37 a (“BDISP 37 a”). The BDISP37 a is located on the inner edge.

The apex point 35 a is separated from the BDISP 37 a by a distance Sfrom 0 millimeter (mm) to less than 8.0 mm.

In an embodiment, the rear panel bottom face 26 c includes an apex point35 c similar to the apex point 35 c on the front panel bottom face 26 a.The rear panel bottom face 26 c includes a first line C defined by theinner edge of the 29 c first peripheral tapered seal 40 c and a secondline D defined by the inner edge 29 d of the second peripheral taperedseal 40 d. The first line C intersects the second line D at an apexpoint 35 c in the bottom seal area 33. The rear panel bottom face 26 chas a bottom distalmost inner seal point 37 c (“BDISP 37 c”). The BDISP37 c is located on the inner edge. The apex point 35 c is separated fromthe BDISP 37 c by a distance T from 0 millimeter (mm) to less than 8.0mm.

It is understood the following description to the front panel bottomface 26 a applies equally to the rear panel bottom face 26 c, withreference numerals to the rear panel bottom face 26 c shown in adjacentclosed parentheses.

In an embodiment, the BDISP 37 a (37 c) is located where the inner edges29 a (29 c) and 29 b (29 d) intersect. The distance S (distance T)between the BDISP 37 a (37 c) and the apex point 35 a (35 c) is 0 mm.

In an embodiment, the inner seal edge diverges from the inner edges 29a, 29 b (29 c, 29 d), to form an inner seal arc 39 a (front panel) andinner seal arc 39 c (rear panel) as shown in FIGS. 4 and 6. The BDISP 37a (37 c) is located on the inner seal arc 39 a (39 c). The apex point 35a (apex point 35 c) is separated from the BDISP 37 a (BDISP 37 c) by thedistance S (distance T), which is from greater than 0 mm, or 0.5 mm, or1.0 mm, or 2.0 mm, or 2.6 mm, or 3.0 mm, or 3.5 mm, or 3.9 mm to 4.0 mm,or 4.5 mm, or 5.0 mm, or 5.2 mm, or 5.3 mm, or 5.5 mm, or 6.0 mm, or 6.5mm, or 7.0 mm, or 7.5 mm, or 7.9 mm.

In an embodiment, apex point 35 a (35 c) is separated from the BDISP 37a (37 c) by the distance S (distance T), which is from greater than 0 mmto less than 6.0 mm.

In an embodiment, the distance S (distance T) from the apex point 35 a(35 c) to the BDISP 37 a (37 c) is from greater than 0 mm, or 0.5 mm or1.0 mm, or 2.0 mm to 4.0 mm, or 5.0 mm, or less than 5.5 mm.

In an embodiment, apex point 35 a (apex point 35 c) is separated fromthe BDISP 37 a (BDISP 37 c) by the distance S (distance T), which isfrom 3.0 mm, or 3.5 mm, or 3.9 mm to 4.0 mm, or 4.5 mm, or 5.0 mm, or5.2 mm, or 5.3 mm, or 5.5 mm.

In an embodiment, the distal inner seal arc 39 a (39 c) has a radius ofcurvature from 0 mm, or greater than 0 mm, or 1.0 mm to 19.0 mm, or 20.0mm.

In an embodiment, each peripheral tapered seal 40 a-40 d (outside edge)and an extended line from respective peripheral seal 41 (outside edge)form an angle Z, as shown in FIG. 1. The angle Z is from 40°, or 42°, or44°, or 45° to 46°, or 48°, or 50°. In an embodiment, angle Z is 45°.

The bottom segment 26 includes a pair of gussets 54 and 56 formed thereat, which are essentially extensions of the bottom faces 26 a-26 d. Thegussets 54 and 56 can facilitate the ability of the flexible container10 to stand upright. These gussets 54 and 56 are formed from excessmaterial from each bottom face 26 a-26 d that are joined together toform the gussets 54 and 56. The triangular portions of the gussets 54and 56 comprise two adjacent bottom segment panels sealed together andextending into its respective gusset. For example, adjacent bottom faces26 a and 26 d extend beyond the plane of their bottom surface along anintersecting edge and are sealed together to form one side of a firstgusset 54. Similarly, adjacent bottom faces 26 c and 26 d extend beyondthe plane of their bottom surface along an intersecting edge and aresealed together to form the other side of the first gusset 54. Likewise,a second gusset 56 is similarly formed from adjacent bottom faces 26a-26 b and 26 b-26 c. The gussets 54 and 56 can contact a portion of thebottom segment 26, where the gussets 54 and 56 can contact bottom faces26 b and 26 d covering them, while bottom segment panels 26 a and 26 cremain exposed at the bottom end 46.

As shown in FIG. 4, the gussets 54 and 56 of the flexible container 10can further extend into the bottom handle 14. In the aspect where thegussets 54 and 56 are positioned adjacent bottom segment panels 26 b and26 d, the bottom handle 14 can also extend across bottom faces 26 b and26 d, extending between the pair of panels 18 and 20. The bottom handle14 can be positioned along a center portion or midpoint of the bottomsegment 26 between the front panel 22 and the rear panel 24.

The top handle 12 and the bottom handle 14 can comprise up to four plysof film sealed together for a four panel container 10. When more thanfour panels are used to make the container, the handles 12, 14 caninclude the same number of panels used to produce the container. Anyportion of the handles 12, 14 where all four plys are not completelysealed together by the heat-sealing method, can be adhered together inany appropriate manner, such as by a tack seal to form a fully-sealedmultilayer handle. Alternatively, the top handle 12 can be made from asfew as a single ply of film from one panel only or can be made from onlytwo plies of film from two panels. The handles 12, 14 can have anysuitable shape and generally will take the shape of the film end. Forexample, typically the web of film has a rectangular shape when unwound,such that its ends have a straight edge. Therefore, the handles 12, 14would also have a rectangular shape.

Additionally, the bottom handle 14 can contain a handle opening 16 orcutout section therein sized to fit a user's hand, as can be seen inFIG. 1. The handle opening 16 can be any shape that is convenient to fitthe hand and, in one aspect, the handle opening 16 can have a generallyoval shape. In another embodiment, the handle opening 16 can have agenerally rectangular shape. Additionally, the handle opening 16 of thebottom handle 14 can also have a flap 38 that comprises the cut materialthat forms the handle opening 16. To define the handle opening 16, thebottom handle 14 can have a section that is cut out of the multilayerbottom handle 14 along three sides or portions while remaining attachedat a fourth side or lower portion. This provides a flap of material 38that can be pushed through the handle opening 16 by the user and foldedover an edge of the handle opening 16 to provide a relatively smoothgripping surface at an edge that contacts the user's hand. If the flapof material 38 were completely cut out, this would leave an exposedfourth side or lower edge that could be relatively sharp and couldpossibly cut or scratch the hand when placed there.

Furthermore, a portion of the bottom handle 14 attached to the bottomsegment 26 can contain a dead machine fold 42 or a score line thatprovides for the bottom handle 14 to consistently fold in the samedirection, as illustrated in FIG. 3. The machine fold 42 can comprise afold line that permits folding in a first direction X toward the frontpanel 22 and restricts folding in a second direction Y toward the rearpanel 24. The term “restricts,” as used throughout this application, canmean that it is easier to move in one direction, or the first directionX, than in an opposite direction, such as the second direction Y. Themachine fold 42 can cause the bottom handle 14 to consistently fold inthe first direction X because it can be thought of as providing agenerally permanent fold line in the bottom handle 14 that ispredisposed to fold in the first direction X, rather than in the seconddirection Y. This machine fold 42 of the bottom handle 14 can servemultiple purposes, one being that when a user is transferring theproduct from the container 10 they can grasp the bottom handle 14 and itwill easily bend in the first direction X to assist in pouring.Secondly, when the flexible container 10 is stored in an uprightposition, the machine fold 42 in the bottom handle 14 encourages thebottom handle 14 to fold in the first direction X along the machine fold42, such that the bottom handle 14 can fold underneath the container 10adjacent one of the bottom segment panels 26 a, as shown in FIG. 4. Theweight of the product can also apply a force to the bottom handle 14,such that the weight of the product can further press on the bottomhandle 14 and maintain the bottom handle 14 in the folded position inthe first direction X. As will be discussed herein, the top handle 12can also contain a similar machine fold 34 a, 34 b that also allows itto fold consistently in the same first direction X as the bottom handle14.

Additionally, as the flexible container 10 is evacuated and less productremains, the bottom handle 14 can continue to provide support to helpthe flexible container 10 to remain standing upright unsupported andwithout tipping over. Because the bottom handle 14 is sealed generallyalong its entire length extending between the pair of gusset panels 18and 20, it can help to keep the gussets 54 and 56 (FIGS. 3, 4) togetherand continue to provide support to stand the container 10 upright, evenas the container 10 is emptied.

As seen in FIGS. 1, 3, and 5, the top handle 12 can extend from the topsegment 28 and, in particular, can extend from the four panels 28 a-28 dthat make up the top segment 28. The four panels 28 a-28 d of film thatextend into the top handle 12 are all sealed together to form amultilayer top handle 12. The top handle 12 can have a U-shape and, inparticular, an upside down U-shape with a horizontal upper handleportion 12 a having two pairs of spaced legs 13 and 15 extendingtherefrom. The pair of legs 13 and 15 extend from the top segment 28,adjacent the neck 30.

A portion of the top handle 12 can extend above the neck 30 and abovethe top segment 28 when the top handle 12 is extended in a positionperpendicular to the top segment 28 and, in particular, the entire upperhandle portion 12 a can be above the neck wall 50 and the top segment28. The two pairs of legs 13 and 15 along with the upper handle portion12 a together make up the top handle 12 surrounding a handle openingthat allows a user to place their hand therethrough and grasp the upperhandle portion 12 a of the handle 12.

As with the bottom handle 14, the top handle 12 also can have a deadmachine fold 34 a, 34 b that permits folding in a first direction towardthe front side panel 22 and restricts folding in a second directiontoward the rear side panel 24, as shown in FIG. 5. The machine fold 34a, 34 b can be located in each of the pair of legs 13, 15 at a locationwhere the seal begins. The top handle 12 can be adhered together, suchas with a tack adhesive, for example. The machine fold 34 a, 34 b in thetop handle 12 can allow for the top handle 12 to be inclined to fold orbend consistently in the same first direction X as the bottom handle 14,rather than in the second direction Y. As shown in FIGS. 1, 3, and 5,the top handle 12 can likewise contain a flap portion 36 that foldsupwards toward the upper handle portion 12 a of the top handle 12 tocreate a smooth gripping surface of the top handle 12, as with thebottom handle 14, such that the handle material is not sharp and canprotect the user's hand from getting cut on any sharp edges of the tophandle 12.

When the container 10 is in a rest position, such as when it is standingupright on its bottom segment 26, as shown in FIG. 3, the bottom handle14 can be folded underneath the container 10 along the bottom machinefold 42 in the first direction X, so that it is parallel to the bottomsegment 26 and adjacent bottom panel 26 a, and the top handle 12 willautomatically fold along its machine fold 34 a, 34 b in the same firstdirection X, with a front surface of the top handle 12 parallel to apanel 28 a of the top segment 28. The top handle 12 folds in the firstdirection X, rather than extending straight up, perpendicular to the topsegment 28, because of the machine fold 34 a, 34 b. Both handles 12 and14 are inclined to fold in the same direction X, such that upondispensing, the handles can fold the same direction, relatively parallelto its respective end panel or end segment, to make dispensing easierand more controlled. Therefore, in a rest position, the handles 12 and14 are both folded generally parallel to one another. Additionally, thecontainer 10 can stand upright even with the bottom handle 14 positionedunderneath the upright container 10.

The material of construction of the flexible container 10 can comprisefood-grade plastic. For instance, nylon, polypropylene, polyethylenesuch as high density polyethylene (HDPE) and/or low density polyethylene(LDPE) may be used, as discussed later. The film of the plasticcontainer 10 can have a thickness and barrier properties that areadequate to maintain product and package integrity during manufacturing,distribution, product shelf life and customer usage. In an embodiment,the flexible multilayer film has a thickness from 100 micrometers (μm),or 200 μm, or 250 μm to 300 μm, or 350 μm, or 400 μm. In an embodiment,the film material can also be such that it provides the appropriateatmosphere within the flexible container 10 to maintain the productshelf life of at least about 180 days. Such films can comprise an oxygenbarrier film, such as a film having a low oxygen transmission rate (OTR)from greater than 0 to 0.4 cc/m²/atm/24 hrs at 23° C. and 80% relativehumidity (RH). Additionally, the flexible multilayer film can alsocomprise a water vapor barrier film, such as a film having a low watervapor transmission rate (WVTR) from greater than 0 to 15 g/m²/24 hrs at38° C. and 90% RH. Moreover, it may be desirable to use materials ofconstruction having oil and/or chemical resistance particularly in theseal layer, but not limited to just the seal layer. The flexiblemultilayer film can be either printable or compatible to receive apressure sensitive label or other type of label for displaying ofindicia on the flexible container 10. In an embodiment, the film canalso be made of non-food grade resins for producing containers formaterials other than food.

In an embodiment, each panel is made from a flexible multilayer filmhaving at least one, or at least two, or at least three layers. Theflexible multilayer film is resilient, flexible, deformable, andpliable. The structure and composition of the flexible multilayer filmfor each panel 18, 20, 22, 24 may be the same or different. For example,each of the four panels 18, 20, 22, 24 can be made from a separate web,each web having a unique structure and/or unique composition, finish, orprint. Alternatively, each of the four panels 18, 20, 22, 24 can be thesame structure and the same composition.

In an embodiment, each panel 18, 20, 22, 24 is a flexible multilayerfilm having the same structure and the same composition.

The flexible multilayer film may be (i) a coextruded multilayerstructure or (ii) a laminate, or (iii) a combination of (i) and (ii). Inan embodiment, the flexible multilayer film has at least three layers: aseal layer, an outer layer, and a tie layer between. The tie layeradjoins the seal layer to the outer layer. The flexible multilayer filmmay include one or more optional inner layers disposed between the seallayer and the outer layer.

In an embodiment, the flexible multilayer film is a coextruded filmhaving at least two, or three, or four, or five, or six, or seven toeight, or nine, or ten, or eleven, or more layers. Some methods, forexample, used to construct films are by cast co-extrusion or blownco-extrusion methods, adhesive lamination, extrusion lamination, thermallamination, and coatings such as vapor deposition. Combinations of thesemethods are also possible. Film layers can comprise, in addition to thepolymeric materials, additives such as stabilizers, slip additives,antiblocking additives, process aids, clarifiers, nucleators, pigmentsor colorants, fillers and reinforcing agents, and the like as commonlyused in the packaging industry. It is particularly useful to chooseadditives and polymeric materials that have suitable organoleptic and/oroptical properties.

In another embodiment, the flexible multilayer film can comprise abladder, wherein two or more films that are adhered in such a manner asto allow some delamination of one or more plies to occur during asignificant impact such that the inside film maintains integrity andcontinues to hold contents of the container.

The flexible multilayer film is composed of a polymeric material.Nonlimiting examples of suitable polymeric materials for the seal layerinclude olefin-based polymer (including any ethylene/C₃-C₁₀ α-olefincopolymers linear or branched), propylene-based polymer (includingplastomer and elastomer, random propylene copolymer, propylenehomopolymer, and propylene impact copolymer), ethylene-based polymer(including plastomer and elastomer, high density polyethylene (“HDPE”),low density polyethylene (“LDPE”), linear low density polyethylene(“LLDPE”), medium density polyethylene (“MDPE”)), ethylene-acrylic acidor ethylene-methacrylic acid and their ionomers with zinc, sodium,lithium, potassium, magnesium salts, ethylene vinyl acetate copolymers,and blends thereof.

Nonlimiting examples of suitable polymeric material for the outer layerinclude those used to make biaxially or monoaxially oriented films forlamination as well as coextruded films. Some nonlimiting polymericmaterial examples are biaxially oriented polyethylene terephthalate(OPET), monoaxially oriented nylon (MON), biaxially oriented nylon(BON), and biaxially oriented polypropylene (BOPP). Other polymericmaterials useful in constructing film layers for structural benefit arepolypropylenes (such as propylene homopolymer, random propylenecopolymer, propylene impact copolymer, thermoplastic polypropylene (TPO)and the like), propylene-based plastomers (e.g., VERSIFY™ orVISTAMAX™)), polyamides (such as Nylon 6; Nylon 6,6; Nylon 6,66; Nylon6,12; Nylon 12; etc.), polyethylene norbornene, cyclic olefincopolymers, polyacrylonitrile, polyesters, copolyesters (such aspolyethylene terephthlate glycol-modified (PETG)), cellulose esters,polyethylene and copolymers of ethylene (e.g., LLDPE based on ethyleneoctene copolymer such as DOWLEX™), blends thereof; and multilayercombinations thereof.

Nonlimiting examples of suitable polymeric materials for the tie layerinclude functionalized ethylene-based polymers such as ethylene-vinylacetate (EVA) copolymer, polymers with maleic anhydride-grafted topolyolefins such as any polyethylene, ethylene-copolymers, orpolypropylene, and ethylene acrylate copolymers such an ethylene methylacrylate (EMA) copolymer, glycidyl containing ethylene copolymers,propylene and ethylene based olefin block copolymers (OBC) such asINTUNE™ (PP-OBC) and INFUSE™ (PE-OBC), both available from The DowChemical Company, and blends thereof.

The flexible multilayer film may include additional layers which maycontribute to the structural integrity or provide specific properties.The additional layers may be added by direct means or by usingappropriate tie layers to the adjacent polymer layers. Polymers whichmay provide additional mechanical performance such as stiffness oropacity, as well polymers which may offer gas barrier properties orchemical resistance can be added to the structure.

Nonlimiting examples of suitable material for the optional barrier layerinclude copolymers of vinylidene chloride and methyl acrylate, methylmethacrylate or vinyl chloride (e.g., SARAN resins available from TheDow Chemical Company); vinylethylene vinyl alcohol (EVOH) copolymer; andmetal foil (such as aluminum foil). Alternatively, modified polymericfilms such as vapor deposited aluminum or silicon oxide on such films asBON, OPET, or oriented polypropylene (OPP), can be used to obtainbarrier properties when used in laminate multilayer film.

In an embodiment, the flexible multilayer film includes a seal layerselected from LLDPE (sold under the trade name DOWLEX™ (The Dow ChemicalCompany)); single-site LLDPE; substantially linear, or linear ethylenealpha-olefin copolymers, including polymers sold under the trade nameAFFINITY′″ or ELITE′″ (The Dow Chemical Company) for example;propylene-based plastomers or elastomers such as VERSIFY™ (The DowChemical Company); and blends thereof. An optional tie layer is selectedfrom either ethylene-based olefin block copolymer PE-OBC (sold asINFUSE™) or propylene-based olefin block copolymer PP-OBC (sold asINTUNE™). The outer layer includes greater than 50 wt % of resin(s)having a melting point, Tm, that is from 25° C., to 30° C., or 40° C.higher than the melting point of the polymer in the seal layer, whereinthe outer layer polymer is selected from resins such as VERSIFY™ orVISTAMAX™, ELITE™, HDPE or a propylene-based polymer such as propylenehomopolymer, propylene impact copolymer or TPO.

In an embodiment, the flexible multilayer film is co-extruded.

In an embodiment, flexible multilayer film includes a seal layerselected from LLDPE (sold under the trade name DOWLEX™ (The Dow ChemicalCompany)); single-site LLDPE; substantially linear, or linear, olefinpolymers, including polymers sold under the trade name AFFINITY™ orELITE™ (The Dow Chemical Company) for example; propylene-basedplastomers or elastomers such as VERSIFY™ (The Dow Chemical Company);and blends thereof. The flexible multilayer film also includes an outerlayer that is a polyamide.

In an embodiment, the flexible multilayer film is a coextruded film andincludes:

(i) a seal layer composed of an olefin-based polymer having a first melttemperature less than 105° C., (Tm1); and

(ii) an outer layer composed of a polymeric material having a secondmelt temperature, (Tm2),

wherein Tm2−Tm1>40° C.

The term “Tm2−Tm1” is the difference between the melt temperature of thepolymer in the outer layer and the melt temperature of the polymer inthe seal layer, and is also referred to as “ΔTm.” In an embodiment, theΔTm is from 41° C., or 50° C., or 75° C., or 100° C. to 125° C., or 150°C., or 175° C., or 200° C.

In an embodiment, the flexible multilayer film is a coextruded film, theseal layer is composed of an ethylene-based polymer, such as a linear ora substantially linear polymer, or a single-site catalyzed linear orsubstantially linear polymer of ethylene and an alpha-olefin monomersuch as 1-butene, 1-hexene or 1-octene, having a Tm from 55° C. to 115°C. and a density from 0.865 to 0.925 g/cm³, or from 0.875 to 0.910g/cm³, or from 0.888 to 0.900 g/cm³ and the outer layer is composed of apolyamide having a Tm from 170° C. to 270° C.

In an embodiment, the flexible multilayer film is a coextruded and/orlaminated film having at least five layers, the coextruded film having aseal layer composed of an ethylene-based polymer, such as a linear orsubstantially linear polymer, or a single-site catalyzed linear orsubstantially linear polymer of ethylene and an alpha-olefin comonomersuch as 1-butene, 1-hexene or 1-octene, the ethylene-based polymerhaving a Tm from 55° C. to 115° C. and a density from 0.865 to 0.925g/cm³, or from 0.875 to 0.910 g/cm³, or from 0.888 to 0.900 g/cm³ and anoutermost layer composed of a material selected from LLDPE, OPET, OPP(oriented polypropylene), BOPP, polyamide, and combinations thereof.

In an embodiment, the flexible multilayer film is a coextruded and/orlaminated film having at least seven layers. The seal layer is composedof an ethylene-based polymer, such as a linear or substantially linearpolymer, or a single-site catalyzed linear or substantially linearpolymer of ethylene and an alpha-olefin comonomer such as 1-butene,1-hexene or 1-octene, the ethylene-based polymer having a Tm from 55° C.to 115° C. and density from 0.865 to 0.925 g/cm³, or from 0.875 to 0.910g/cm³, or from 0.888 to 0.900 g/cm³. The outer layer is composed of amaterial selected from LLDPE, OPET, OPP (oriented polypropylene), BOPP,polyamide, and combinations thereof.

In an embodiment, the flexible multilayer film is a coextruded (orlaminated) five layer film, or a coextruded (or laminated) seven layerfilm having at least two layers containing an ethylene-based polymer.The ethylene-based polymer may be the same or different in each layer.

In an embodiment, the flexible multilayer film includes a seal layercomposed of an ethylene-based polymer, or a linear or substantiallylinear polymer, or a single-site catalyzed linear or substantiallylinear polymer of ethylene and an alpha-olefin monomer such as 1-butene,1-hexene or 1-octene, having a heat seal initiation temperature (HSIT)from 65° C. to less than 125° C. Applicant discovered that the seallayer with an ethylene-based polymer with a HSIT from 65° C. to lessthan 125° C. advantageously enables the formation of secure seals andsecure sealed edges around the complex perimeter of the flexiblecontainer. The ethylene-based polymer with HSIT from 65° C. to less than125° C. is a robust sealant which also allows for better sealing to therigid fitment which is prone to failure. The ethylene-based polymer withHSIT from 65° C. to 125° C. enables lower heat sealingpressure/temperature during container fabrication. Lower heat sealpressure/temperature results in lower stress at the fold points of thegusset, and lower stress at the union of the films in the top segmentand in the bottom segment. This improves film integrity by reducingwrinkling during the container fabrication. Reducing stresses at thefolds and seams improves the finished container mechanical performance.The low HSIT ethylene-based polymer seals at a temperature below whatwould cause the outer layer to be compromised.

In an embodiment, the flexible multilayer film is a coextruded and/orlaminated five layer, or a coextruded (or laminated) seven layer filmhaving at least one layer containing a material selected from LLDPE,OPET, OPP (oriented polypropylene), BOPP, and polyamide.

In an embodiment, the flexible multilayer film is a coextruded and/orlaminated five layer, or a coextruded (or laminated) seven layer filmhaving at least one layer containing OPET or OPP.

In an embodiment, the flexible multilayer film is a coextruded (orlaminated) five layer, or a coextruded (or laminated) seven layer filmhaving at least one layer containing polyamide.

In an embodiment, the flexible multilayer film is a seven-layercoextruded (or laminated) film with a seal layer composed of anethylene-based polymer, or a linear or substantially linear polymer, ora single-site catalyzed linear or substantially linear polymer ofethylene and an alpha-olefin monomer such as 1-butene, 1-hexene or1-octene, having a Tm from 90° C. to 106° C. The outer layer is apolyamide having a Tm from 170° C. to 270° C. The film has a ΔTm from40° C. to 200° C. The film has an inner layer (first inner layer)composed of a second ethylene-based polymer, different than theethylene-based polymer in the seal layer. The film has an inner layer(second inner layer) composed of a polyamide the same or different tothe polyamide in the outer layer. The seven layer film has a thicknessfrom 100 micrometers to 250 micrometers.

FIG. 6 shows an enlarged view of the bottom seal area 33 (Area 6) ofFIG. 1 and the front panel 26 a. The fold lines 60 and 62 of respectivegusset panels 18, 20 are separated by a distance U that is from 0 mm, orgreater than 0 mm, or 0.5 mm, or 1.0 mm, or 2.0 mm, or 3.0 mm, or 4.0mm, or 5.0 mm to 12.0 mm, or greater than 60.0 mm (for largercontainers, for example). In an embodiment, distance U is from greaterthan 0 mm to less than 6.0 mm. FIG. 6 shows line A (defined by inneredge 29 a) intersecting line B (defined by inner edge 29 b) at apexpoint 35 a. BDISP 37 a is on the distal inner seal arc 39 a. Apex point35 a is separated from BDISP 37 a by a distance S having a length fromgreater than 0 mm, or 1.0 mm, or 2.0 mm, or 2.6 mm, or 3.0 mm, or 3.5mm, or 3.9 mm to 4.0 mm, or 4.5 mm, or 5.0 mm, or 5.2 mm, or 5.5 mm, or6.0 mm, or 6.5 mm, or 7.0 mm, or 7.5 mm, or 7.9 mm.

In FIG. 6, an overseal 64 is formed where the four peripheral taperedseals 40 a-40 d converge in the bottom seal area 33. The overseal 64includes 4-ply portions 66, where a portion of each panel is heat sealedto a portion of every other panel. Each panel represents 1-ply in the4-ply heat seal. The overseal 64 also includes a 2-ply portion 68 wheretwo panels (front panel 22 and rear panel 24) are sealed together.Consequently, the “overseal,” as used herein, is the area where theperipheral tapered seals 40 a-40 d converge that is subjected to asubsequent heat seal operation (and subjected to at least two heat sealoperations altogether). The overseal is located in the peripheraltapered seals 40 a-40 d and does not extend into the chamber of theflexible container 10.

In an embodiment, the apex point 35 a is located above the overseal 64.The apex point 35 a is separated from, and does not contact the overseal64. The BDISP 37 a is located above the overseal 64. The BDISP 37 a isseparated from and does not contact the overseal 64.

In an embodiment, the apex point 35 a is located between the BDISP 37 aand the overseal 64, wherein the overseal 64 does not contact the apexpoint 35 a and the overseal 64 does not contact the BDISP 37 a.

The distance between the apex point 35 a to the top edge of the overseal64 is defined as distance W, shown in FIG. 6. In an embodiment, thedistance W has a length from 0 mm, or greater than 0 mm, or 2.0 mm, or4.0 mm to 6.0 mm, or 8.0 mm, or 10.0 mm or 15.0 mm.

When more than four webs are used to produce the container, the portion68 of the overseal 64 may be a 4-ply, or a 6-ply, or an 8-ply portion.

In an embodiment, the flexible container 10 has a vertical drop testpass rate from 90%, or 95% to 100%. The vertical drop test is conductedas follows. The container is filled with tap water to its nominalcapacity, conditioned at 25° C. for at least 3 hours, held in uprightposition from its top handle 12 at 1.5 m height (from the base or sideof the container to the ground), and released to a free fall drop onto aconcrete slab floor. If any leak is detected immediately after the drop,the test is recorded as a failure. A minimum of twenty flexiblecontainers are tested. A percentage for pass/fail containers is thencalculated.

In an embodiment, the flexible container 10 has a side drop pass ratefrom 90%, or 95% to 100%. This side drop test is conducted as follows.The container is filled with tap water to its nominal capacity,conditioned at 25° C. for at least 3 hours, held in upright positionfrom its top handle 12. The flexible container is released on its sidefrom a 1.5 m height to a free fall drop onto a concrete slab floor. Ifany leak is detected immediately after the drop, the test is recorded asfailure. A minimum of twenty flexible containers are tested. Apercentage for pass/fail containers is then calculated.

In an embodiment, the flexible container 10 passes the stand-up testwhere the package is filled with water at ambient temperature and placedon a flat surface for seven days and it should remain in the sameposition, with unaltered shape or position.

In an embodiment, the flexible container 10 has a volume from 0.050liters (L), or 0.1 L, or 0.15 L, or 0.2 L, or 0.25 L, or 0.5 L, or 0.75L, or 1.0 L, or 1.5 L, or 2.5 L, or 3 L, or 3.5 L, or 4.0 L, or 4.5 L,or 5.0 L to 6.0 L, or 7.0 L, or 8.0 L, or 9.0 L, or 10.0 L, or 20 L, or30 L.

The flexible container 10 can be used to store any number of flowablesubstances therein. In particular, a flowable food product can be storedwithin the flexible container 10. In one aspect, flowable food productssuch as salad dressings; sauces; dairy products; mayonnaise; mustard;ketchup; other condiments; syrup; beverages such as water, juice, milk,carbonated beverages, beer, or wine; animal feed; pet feed; and the likecan be stored inside of the flexible container 10.

The flexible container 10 is suitable for storage of other flowablesubstances including, but not limited to, oil, paint, grease, chemicals,suspensions of solids in liquid, and solid particulate matter (powders,grains, granular solids).

The flexible container 10 is suitable for storage of flowable substanceswith higher viscosity and requiring application of a squeezing force tothe container in order to discharge. Nonlimiting examples of suchsqueezable and flowable substances include grease, butter, margarine,soap, shampoo, animal feed, sauces, and baby food.

2. Fitment

The present flexible container includes a fitment 70 inserted into theneck 30 of the flexible container 10. The fitment 70 includes a base 72and a top portion 74, as shown in FIG. 7. The fitment 70 is composed ofone or more polymeric materials. The base 72 and the top portion 74 maybe made from the same polymeric material or from different polymericmaterials. In an embodiment, the base 72 and the top portion 74 are madefrom the same polymeric material.

The top portion 74 may include threads 75 or other suitable structurefor attachment to a closure. Nonlimiting examples of suitable fitmentsand closures, include, screw cap, flip-top cap, snap cap, liquid orbeverage dispensing fitments (stop-cock or thumb plunger), Colderfitment connector, tamper evident pour spout, vertical twist cap,horizontal twist cap, aseptic cap, vitop press, press tap, push on tap,lever cap, conro fitment connector, and other types of removable (andoptionally reclosable) closures. The closure and/or fitment 70 may ormay not include a gasket. In an embodiment, the closure is watertight.In a further embodiment, the closure provides a hermetic seal to thecontainer 10.

The base 72 has a cross sectional shape. The cross sectional shape ofthe base 72 is selected from ellipse, circle, and regular polygon.

In an embodiment, the cross-sectional shape of the base 72 is anellipse. An “ellipse,” as used herein, is a plane curve such that thesums of the distances of each point in its periphery from two fixedpoints, the foci, are equal. The ellipse has a center which is themidpoint of the line segment linking the two foci. The ellipse has amajor axis (the longest diameter through the center). The minor axis isthe shortest line through the center. The ellipse center is theintersection of the major axis and the minor axis. As used herein, thediameter (d) for the ellipse is the major axis.

In an embodiment, the cross-sectional shape is slightly elliptical wherethe ratio of major axis to minor axis is between 1.01 to 1.25.

In an embodiment, the cross-sectional shape for the base 72 is a circle(or is substantially a circle). A “circle,” as used herein, is a closedplane curve consisting of all points at a given distance from a pointwithin it called the center. The radius (r) for the circle is thedistance from the center of the circle to any point on the circle. Thediameter (d) for the circle is 2r.

In an embodiment, the cross sectional shape for the base is a regularpolygon. A “polygon,” as used herein, is a closed plane figure, havingthree or more straight sides. The point where two sides meet is a“vertex.” A “regular polygon,” as used herein, is a polygon that isequiangular (all angles are equal in measure) and equilateral (all sideshave the same length.

The radius (r) for a regular polygon is defined by Formula (1) below.

$\begin{matrix}{{radius} = \frac{s}{2{\sin \left( \frac{\pi}{n} \right)}}} & {{Formula}\mspace{14mu} (1)}\end{matrix}$

-   -   wherein    -   s is the length of any side;    -   n is the number of sides; and    -   sin is the sine function.

The diameter (d) for a regular polygon is 2(r) wherein the radius, r,for the regular polygon is determined by way of Formula (1). Nonlimitingexamples of suitable regular polygon shapes for the cross-section of thebase 72 include equilateral triangular, regular square, regularpentagon, regular hexagon, regular heptagon, regular octagon, regularnonagon, regular decagon, regular hendecagon, or regular dodecagonshape.

The cross-sectional shape of the top portion 74 may be the same ordifferent than the cross-sectional shape of the base 72.

The cross-sectional shape of the base 72 may be circular, slightlyelliptical, or regular polygonal. In an embodiment, the cross-sectionalshape of the base 72 is circular, or substantially circular, as shown inFIGS. 7 and 8.

The base 72 with a circular or regular polygon cross-sectional shape isdistinct from fitments with a canoe-shaped fitment base or fitments witha base having opposing radial fins. In an embodiment, the fitment 70excludes fitments that include a canoe-shaped base, fitments with a basethat has radial fins, fitments with a wing-shaped base, and fitmentswith an eye-shaped base.

The outer surface of the base 72 may or may not include surface texture.In an embodiment, the outer surface of the base 72 has surface texture.Nonlimiting examples of surface texture include embossment, and aplurality of radial ridges to promote sealing to the inner surface ofthe neck wall 50.

In an embodiment, the outer surface of base 72 is smooth and does notinclude surface texture, as shown in FIG. 7.

In an embodiment, the diameter of the base 72 is greater than thediameter of the top portion 74. FIG. 8 shows a base 72 with circlecross-sectional shape and the diameter of base 72 is G having a lengththat is greater than the length of the diameter Q, the diameter of thetop portion 74. The fitment 70 with a base diameter G that is greaterthan top portion diameter Q advantageously promotes unimpeded pouring ofcontent from the flexible container 10.

The base 72 is welded, or is otherwise heat sealed to the multilayerfilm that forms the neck 30. In other words, the base 72 is welded tothe neck 30. Heat sealing can be made by means of hot bar, impulse seal,ultrasonic or in some cases by high frequency (HF) sealing.

In an embodiment, the base 72 is welded to the neck 30 by way of amandrel with an expandable collar as disclosed in co-pending case, U.S.Ser. No. 62/146,002, filed on 10 Apr. 2015, the entire content of whichis incorporated by reference herein.

The fitment 70 is made from a polymeric material. Nonlimiting examplesof suitable polymeric materials include propylene-based polymer,ethylene-based polymer, polyamides (such as Nylon 6; Nylon 6,6; Nylon6,66; Nylon 6,12; Nylon 12; and the like), cyclic olefin copolymers(COC)(such as TOPAS™ or APEL™), polyesters (crystalline and amorphous),copolyester resin (such as PETG), cellulose esters (such as polylacticacid (PLA)), and combinations thereof.

In an embodiment, the fitment 70 is composed of, or is otherwise formedfrom, a propylene-based polymer. Nonlimiting examples of suitablepropylene-based polymer include propylene homopolymer (hPP), impactcopolymer polypropylene (ICP), random copolymer polypropylene (rPPO),propylene-based interpolymer both plastomers or elastomers such asVERSIFY™ (The Dow Chemical Company), syndiotactic polypropylene (sPP),metallocene polypropylene (mPP), thermoplastic polyolefin (TPO), andcombinations thereof.

In an embodiment, the fitment 70 is composed of, or is otherwise formedfrom, a blend of one or more propylene-based polymers, and a modifiercontaining a block composite. A “block composite,” as used herein, is ablock copolymer having from 70-99 wt % of ethylene/propylene (EP) softblocks (with 65 wt % of ethylene, based on the total weight of the EPblock) and from 30-1 wt % of isotactic polypropylene (iPP) hard blocksthat is twin-screw compounded with the olefin modifier resin compositionprior to blending with the propylene-based polymer. Suitable processesuseful in producing the block composites may be found in, U.S. Pat. Nos.8,053,529, 8,686,087, and 8,716,400. The blend can contain greater than0 wt % to 40 wt % block composite. In a further embodiment, the blendincludes 80 wt % of Pro-fax RP448S rPP (available from LyondellBasell)and 20 wt % of the modifier. The compounded modifier includes 30 wt %block composite (The Dow Chemical Company), 50 wt % AFFINITY™ GA 1950(available from The Dow Chemical Company) and 20 wt % ENGAGE™ 8402(available from The Dow Chemical Company). The blend has a transparencyof 99%, a haze of 11% at (0.75 mm) and an Izod Impact Strength @−20° C.of 9 kJ/m², measured according to ASTM D256 on 0.75 mm×76 mm×76 mminjection molded plaques.

In an embodiment, the fitment 70 is composed of, or is otherwise formedfrom, an ethylene-based polymer. Nonlimiting examples of suitableethylene-based polymer include high density polyethylene (“HDPE”),medium density polyethylene (“MDPE”), low density polyethylene (“LDPE”),linear low density polyethylene (“LLDPE”), ultra low densitypolyethylene (“ULDPE”), very low density polyethylene (“VLDPE”),single-site LLDPE, substantially linear, or linear ethylene alpha-olefincopolymers, including polymers sold under the trade name ENGAGE™elastomers, AFFINITY™ plastomers or ELITE′″ Enhanced Polyethylene resins(“EPE”) (all available from The Dow Chemical Company) for example,ethylene-alpha-olefin multi-block copolymer sold as INFUSE™ Olefin BlockCopolymers (available from The Dow Chemical Company), copolymers ofpolyethylene such as ethylene-vinyl acetate (“EVA”) polymer, ethyleneethyl acrylate (“EEA”) polymer or ethylene methyl acrylate (“EMA”)polymer and combinations thereof.

In an embodiment, the fitment 70 is formed from an ethylene-basedpolymer having a 2% secant flexural modulus (ASTM D790) of less than 200megapascal (MPa), or a 2% secant flexural modulus from 10 MPa, or 25MPa, or 50 MPa, or 75 MPa, or 100 MPa to 125 MPa, or 150 MPa, or 175MPa, or 200 MPa. A nonlimiting example of an ethylene-based polymer witha 2% secant flexural modulus from 10 MPa to 200 MPa isethylene/alpha-olefin multi-block copolymer sold under the tradenameINFUSE™ (available from the Dow Chemical Company) such as INFUSE™ 9817.

In an embodiment, the fitment 70 is composed of, or is otherwise formedfrom, a blend of one or more propylene-based polymers, alone, or incombination with one or more ethylene-based polymers. Nonlimitingexamples of such blends include propylene-based polymer such as hPP orrPP or propylene based interpolymer (VERSIFY™) that is blended with from5 wt % to 30 wt % of ethylene based plastomers or elastomers such asAFFINITY™ 1280, AFFINITY™ GA1950, ENGAGE™ 8100, ENGAGE™ 8200, ENGAGE™8401, ENGAGE™ 8402 ENGAGE™ 8411, ENGAGE™ XLT 8677, INFUSE™ 9817 olefinblock copolymer resin, VERSIFY™ 2400, VERSIFY™ 3401 or VERSIFY™ 4301,and combinations thereof.

In an embodiment, the fitment 70 is formed from a compounded blendcontaining 80 wt % of R751-12N rPP (available from Braskem) and 20 wt %ENGAGE™ 8411 (available from The Dow Chemical Company) with atransparency of 99.2+/−0.2%, a haze of 6.9+/−0.4% at 0.5 mm and aGardner Impact @−29° C. of 3.0+/−0.7 J, measured in accordance with ASTMD5420GC at −29° C. using standard ring in method with a 1.8 kg hammer onplaques with the following dimensions: 0.5 mm×60 mm×60 mm.

In an embodiment, the fitment 70 is composed of, or is otherwise formedfrom, a polyamide. Nonlimiting examples of suitable polyamide includeNylon 6; Nylon 6,6; Nylon 6,66; Nylon 6,12; Nylon 12 and the like.

In an embodiment, the fitment 70 is composed of, or is otherwise formedfrom, a copolyester. As used herein, the term “copolyester” is a polymerthat contains repeating units of two or more different polyestermonomers. Nonlimiting examples of suitable copolyesters includecopolyesters formed from aromatic dicarboxylic acids, esters ofdicarboxylic acids, anhydrides of dicarboxylic esters, glycols, andmixtures thereof. Suitable partially aromatic copolyesters are formedfrom repeat units comprising terephthalic acid, dimethyl terephthalate,isophthalic acid, dimethyl isophthalate, dimethyl-2,6naphthalenedicarboxylate, 2,6-naphthalenedicarboxylic acid, 1,2-, 1,3-and 1,4 phenylene dioxydoacetic acid, ethylene glycol, diethyleneglycol, 1,4-cyclohexane-dimethanol, 1,4-butanediol, and neopentyl glycolmixtures thereof.

In an embodiment, the fitment 70 is composed of, or is otherwise formedfrom, a cycle olefin copolymer. Nonlimiting examples of suitable COC'sinclude “COC”, such as TOPAS™ or APEL™

In an embodiment, the copolyester includes polymerization units derivedfrom terephthalic acid (TPA) and, optionally polymerization unitsderived from cyclohexanedimethanol (CHDM), and ethylene glycol (EG), andthe copolyester includes greater than 50 mol % glycol polymerizationunits (such as PETG) or wherein the copolymer includes greater than 50percent by mole of CHDM, such as glycol-modifiedpolycyclohexylenemethylene terephthalate, PCTG.

In an embodiment, the copolyester includes terephthalic acid, Spiroglycol, and ethylene glycol known as SPG-PET available from Mitsubishi.Alternatively, copolyesters can include polymerization units derivedfrom terephthalic acid, cyclohexanedimethanol (CHDM) and isophthalicacid (IPA) such as used to produce PCTA resins.

In an embodiment, the copolyester is polyethylene terephthlateglycol-modified (PETG) such as Eastman's Eastar™ copolyester 6763 with ahaze of 0.8% or a branched PETG such as Provista™ copolymer MP002 with1.3% haze and notched izod at −40° C. of 0.63 J/cm, as determined byASTM D256.

In an embodiment, the copolyester is a PCTG such as Eastman's Eastar™copolyester DN010, with 1.4% haze and notched izod at −40° C. of 0.77J/cm, as determined by ASTM D4812

In an embodiment, the copolyester is a PCTA including DuraStar™ polymerDS2010 (available from Eastman) having haze of 0.3% and notched izod at−40° C. of 0.6 J/cm, as determined by ASTM D256.

In an embodiment, the copolyester is impact modified with from 5 wt % to30 wt % of one or more of the following nonlimiting modifiers:styrene-ethylene/butylene-styrene block copolymers (SEBS) which havebeen functionalized with maleic anhydride (such as KRATON® FG 1901Xsupplied by the Shell Chemical Co.), ethylene methacrylic acidcopolymers (such as SURLYN® ionomer resins supplied by DuPont PolymerProducts like SURLYN® 1601-2 ionomer resin), and butadiene/acrylicmonomer shell core polymers (such as Paraloid® compositions based onbutyl acrylate or methyl acrylate supplied by The Dow Chemical Companylike Paraloid® EXL-3361).

In an embodiment, copolyester has an intrinsic viscosity (IV) from 0.5deca-liters per gram (dl/g), or 0.6 dl/g, or 0.7 dl/g to 0.80 dl/g, or0.85 dl/g, or 0.90 dl/g, or 1.1 dl/g. The copolyester IV is determinedon a 0.5 gram sample in 100 ml of a by weight solution of 60/40phenol/tetrachloroethane at 25° C., as taught in U.S. Patent Publication2003/0141625.

The polymeric material used to make the fitment 70 can include additivessuch as stabilizers (such as hindered phenol or phosphites or blendstherein), slip additives (such as erucamide or polymethyl siloxane),antiblocking additives (such as synthetic silica), process aids,clarifiers, nucleators, crack stopping agents, pigments or colorants,fillers and reinforcing agents, and the like as commonly used in thepackaging industry. It is particularly useful to choose additives andpolymeric materials that have suitable organoleptic properties and canimpart benefit optical properties to the fitment.

In an embodiment, the fitment 70 is formed from any of the foregoingpolymeric materials, the polymeric material having one, some, or all ofthe following properties:

a 2% secant flexural modulus (ASTM D790) from 10 MPa, or 25 MPa, or 50MPa, or 75 MPa, or 100 MPa to 125 MPa, or 150 MPa, or 175 MPa, or 200MPa;

a clarity from 80%, or 83%, or 85%, or 87%, or 89% to 90%, or 92%, or94%, or 96%, or 98%, or 99%, or 99.5%; and

a haze from 0.3%, or 0.5%, or 1.0%, or 3.0%, or 5.0%, or 7.0%, or 9.0%,or 10%, or 11% to 13%, or 15%, or 17%, or 19%, or 20%.

In an embodiment, the fitment 70 is composed of a resin sold under thetradename ELITE™ Enhanced Polyethylene resin, such as ELITE™ 5230G(available from The Dow Chemical Company).

In an embodiment, the fitment 70 includes a polymeric composition havingan Izod impact resistance from greater than 50 Joules (J)/meter (m), or100 J/m, or 150 J/m, or 200 J/m, or 250 J/m to 300 J/m, or 350 J/m, or400 J/m, or 450 J/m, or 500 J/m. Izod impact resistance is measured inaccordance with ASTM D 256. In a further embodiment, the fitmentincludes a polyolefin having an Izod impact resistance from greater than50 J/m, or 100 J/m, or 150 J/m, or 200 J/m, or 250 J/m to 300 J/m, or350 J/m, or 400 J/m, or 450 J/m, or 500 J/m.

In an embodiment, the fitment 70 includes a polymeric compositioncontaining a polyolefin with a melt temperature (Tm) greater than orequal to the melt temperature of the polyolefin present in the seallayer of the multilayer film used to make the panels 18, 20, 22, 24.When clamp heat sealing is utilized to form the seal between the base 72and the neck 30, a nonlimiting example includes a fitment 70 composed ofa HDPE having a Tm of 125° C. and the seal layer for the container 10contains an LDPE with a Tm of 105° C. Another nonlimiting example is afitment 70 composed of LLDPE with Tm of 120° C., and the container 10has a seal layer containing an ethylene/α-olefin copolymer (AFFINITY™ PL1140G) with a Tm 96° C.

In an embodiment, the flexible container 10 includes a hermetic sealbetween the neck 30 and the base 72.

In an embodiment, the polymeric material for the fitment 70 has a hazeas determined by ASTM D1003 (method B) at 0.5 mm thickness from 0.3%, or0.5%, or 1.0%, or 3.0%, or 5.0%, or 7.0%, or 9.0%, or 10%, or 11% to13%, or 15%, or 17%, or 19%, or 20% and also has high clarity where theclarity is determined by ASTM D1746 and clarity is from 80%, or 83%, or85%, or 87%, or 89% to 90%, or 92%, or 94%, or 96%, or 98%, or 99%, or99.5%.

In a further embodiment, the fitment 70 is made from a copolyester resinhaving a haze from 0.3% to 4% and a clarity from 80% to 90%.

In an embodiment, the base 72 has a diameter (d) and a wall thickness(WT) as shown in FIG. 8. In FIG. 8, the base 72 diameter (d) is shown asdistance G and the wall thickness (WT) is shown as the distance H. Thebase 72 diameter (d) can be uniform or can vary along the length of thebase 72. Similarly, the wall thickness (WT) can be uniform or can varyalong the length of the base 72.

In an embodiment, the diameter of the base 72 is uniform along the baselength and the wall thickness (WT) is uniform along the base length.

In an embodiment, the base 72 has a diameter (d) from 5 mm, or 10 mm or20 mm, or 25 mm, or 30 mm, or 35 mm, or 38 mm, or 40 mm, or 45 mm, or 47mm, or 50 mm, or 60 mm, or 70 mm, or 80 mm, or 90 mm to 100 mm, or 110mm, or 125 mm, or 150 mm, or 175 mm, or 200 mm.

In an embodiment, the base 72 has a wall thickness (WT) from 0.15 mm, or0.2 mm, or 0.3 mm, or 0.4 mm, or 0.5 mm, or 0.6 mm, or 0.7 mm, or 0.75mm, or 0.8 mm, or 0.9 mm, or 1.0 mm to 1.3 mm, or 1.5 mm, or 1.7 mm, or1.9 mm, or 2.0 mm.

In an embodiment, the base 72 has a wall thickness (WT) from 0.15 mm, or0.2 mm, or 0.3 mm, or 0.4 mm to 0.5 mm, or 0.6 mm, or 0.7 mm, or 0.75mm. As used herein, a base wall thickness (WT) with the foregoing wallthickness from 0.15 mm to 0.75 mm is a “thin-wall.”

The base 72 has a diameter to wall thickness ratio. The “diameter towall thickness ratio” (denoted as “d/WT”) is the diameter (d) of thebase 72 (in millimeters, mm) divided by the wall thickness (WT), in mm,of the base 72. In an embodiment, the base 72 has a d/WT from 5, or 8,or 10, or 20, or 30, or 40, or 50, or 60, or 70, or 80, or 90, or 100,or 125, or 150, or 175, or 200 to 500, or 525, or 550, or 575, or 600,or 625, or 650, or 675, or 700, or 725, or 750, or 775, or 800, or 825,or 850, or 875, or 900, or 925, or 950, or 975, or 1000, or 1100, or1200, or 1300, or 1400, or 1500, or 1600, or 1700, or 1800, or 1900, or2000.

In an embodiment, the base 72 has a d/WT from 35, or 40, or 50, or 60,or 70, or 80, or 90, or 100, or 125, or 150, or 175 to 200, or 225, or250, or 275, or 300, or 325, or 350, or 375, or 400, or 425, or 450, or475, or 500, or 525, or 550 or 600, or 650, or 700, or 750, or 800.

In an embodiment, the base 72 has a d/WT ratio from 35 to 800, thediameter (d) is from 10 mm, or 20 mm, or 30 mm, or 35 mm, or 38 mm, or40 mm, or 45 mm, or 47 mm, or 50 mm to 60 mm, or 70 mm, or 80 mm, or 90mm, or 100 mm, or 110 mm, or 120 mm; and the wall thickness (WT) is from0.15 mm, or 0.2 mm, or 0.3 mm, or 0.4 mm to 0.5 mm, or 0.6 mm, or 0.7mm, or 0.75 mm. Thus, the base 72 has a thin-wall structure.

In an embodiment, the base 72 has a d/WT ratio from 35 to 800 asdisclosed above. The diameter (d) for the base 72 is from 47 mm to 120mm. The wall thickness (WT) for the base 72 is from 0.15 mm to 0.75 mm.Thus, the base 72 has a thin-wall structure.

In an embodiment, the base 72 has a d/WT ratio from 50 to 550 asdisclosed above. The diameter (d) for the base 72 is from 10 mm to 110mm. The wall thickness (WT) for the base 72 is from 0.2 mm to 0.5 mm.Thus, the base 72 has a thin-wall structure.

The fitment with a d/WT from 35 to 800 can include a base with athin-wall structure. Thin-wall fitments advantageously reduce productioncosts, reduce material cost, and reduce the weight of the final flexiblecontainer 10.

The present flexible container may comprise two or more embodimentsdisclosed herein.

Definitions

The numerical ranges disclosed herein include all values from, andincluding, the lower value and the upper value. For ranges containingexplicit values (e.g., 1, or 2, or 3 to 5, or 6, or 7) any subrangebetween any two explicit values is included (e.g., 1 to 2; 2 to 6; 5 to7; 3 to 7; 5 to 6; etc.).

Unless stated to the contrary, implicit from the context, or customaryin the art, all parts and percents are based on weight, and all testmethods are current as of the filing date of this disclosure.

Clarity is measured in accordance with ASTM-D1746.

The term “composition,” as used herein, refers to a mixture of materialswhich comprise the composition, as well as reaction products anddecomposition products formed from the materials of the composition.

The terms “comprising,” “including,” “having,” and their derivatives,are not intended to exclude the presence of any additional component,step or procedure, whether or not the same is specifically disclosed. Inorder to avoid any doubt, all compositions claimed through use of theterm “comprising” may include any additional additive, adjuvant, orcompound, whether polymeric or otherwise, unless stated to the contrary.In contrast, the term, “consisting essentially of” excludes from thescope of any succeeding recitation any other component, step orprocedure, excepting those that are not essential to operability. Theterm “consisting of” excludes any component, step or procedure notspecifically delineated or listed.

Density is measured in accordance with ASTM D 792.

An “ethylene-based polymer,” as used herein is a polymer that containsmore than 50 mole percent polymerized ethylene monomer (based on thetotal amount of polymerizable monomers) and, optionally, may contain atleast one comonomer.

Haze is measured in accordance with ASTM D1003 (method B) and noting thethickness of the part.

The term “heat seal initiation temperature,” is minimum sealingtemperature required to form a seal of significant strength, in thiscase, 2 lb/in (8.8N/25.4 mm). The seal is performed in a Topwave HTtester with 0.5 seconds dwell time at 2.7 bar (40 psi) seal barpressure. The sealed specimen is tested in an Instron Tensiomer at 10in/min (4.2 mm/sec or 250 mm/min).

Melt flow rate (MFR) is measured I accordance with ASTM D 1238,Condition 280° C./2.16 kg (g/10 minutes).

Melt index (MI) is measured in accordance with ASTM D 1238, Condition190° C./2.16 kg (g/10 minutes).

Tm or “melting point” as used herein (also referred to as a melting peakin reference to the shape of the plotted DSC curve) is typicallymeasured by the DSC (Differential Scanning calorimetry) technique formeasuring the melting points or peaks of polyolefins as described inU.S. Pat. No. 5,783,638. It should be noted that many blends comprisingtwo or more polyolefins will have more than one melting point or peak,many individual polyolefins will comprise only one melting point orpeak.

An “olefin-based polymer,” as used herein is a polymer that containsmore than 50 mole percent polymerized olefin monomer (based on totalamount of polymerizable monomers), and optionally, may contain at leastone comonomer. Nonlimiting examples of olefin-based polymer includeethylene-based polymer and propylene-based polymer.

A “polymer” is a compound prepared by polymerizing monomers, whether ofthe same or a different type, that in polymerized form provide themultiple and/or repeating “units” or “mer units” that make up a polymer.The generic term polymer thus embraces the term homopolymer, usuallyemployed to refer to polymers prepared from only one type of monomer,and the term copolymer, usually employed to refer to polymers preparedfrom at least two types of monomers. It also embraces all forms ofcopolymer, e.g., random, block, etc. The terms “ethylene/α-olefinpolymer” and “propylene/α-olefin polymer” are indicative of copolymer asdescribed above prepared from polymerizing ethylene or propylenerespectively and one or more additional, polymerizable α-olefin monomer.It is noted that although a polymer is often referred to as being “madeof” one or more specified monomers, “based on” a specified monomer ormonomer type, “containing” a specified monomer content, or the like, inthis context the term “monomer” is understood to be referring to thepolymerized remnant of the specified monomer and not to theunpolymerized species. In general, polymers herein are referred to hasbeing based on “units” that are the polymerized form of a correspondingmonomer.

A “propylene-based polymer” is a polymer that contains more than 50 molepercent polymerized propylene monomer (based on the total amount ofpolymerizable monomers) and, optionally, may contain at least onecomonomer.

Some embodiments of the present disclosure will now be described indetail in the following Examples.

Examples

1. Production of Flexible Container (No Fitment)

Four panel flexible containers having a neck and a body as shown inFIGS. 1-6 are formed using the seven-layer film provided in Table 1.Each of the four panels is made with the seven-layer film shown inTable 1. The four-panel flexible containers are produced with a volumeof either 3.875 L or 20 L and are produced by ISO Poly Films (GrayCourt, S.C.). The 3.875 L flexible containers use a 150 micrometer (μm)film and the 20 L containers use both 150 μm and 250 μm film.

TABLE 1 Composition of flexible multilayer film for flexible containerpanels (7 layer co-extruded flexible multilayer film) OverallDescription % Thickness Weight % Layer Density ULTRAMID C33L01 Nylon6/66 viscosity number 195 cm³/g (ISO 13.0% 15.3% 1 1.12 307 @ 0.5% in96% H₂SO₄), melting point 196° C. (ISO 3146) AMPLIFY TY1352 Maleicanhydride grafted polyethylene 0.922 12.0% 11.6% 2 0.922 g/cm³; 1.0 MI @2.16 Kg 190° C., melting point 125° C. ELITE 5400G Polyethylene density0.916 g/cm³; 20.0% 19.2% 3 0.916 1.0 MI @ 2.16 Kg 190° C., melting point123° C. AMPLIFY TY1352 Maleic anhydride grafted polyethylene 0.922 12.0%11.6% 4 0.922 g/cm³; 1.0 MI @ 2.16 Kg 190° C., melting point 125° C.ULTRAMID C33L01 Nylon 6/66 viscosity number 195 cm³/g (ISO 6.0% 7.0% 51.12 307 @0.5% in 96% H₂SO₄), melting point 196° C. (ISO 3146) AMPLIFYTY1352 Maleic anhydride grafted polyethylene 0.922 12.0% 11.6% 6 0.922g/cm³; 1.0 MI @ 2.16 Kg 190° C., melting point 125° C. AFFINITY PF1146GEthylene alpha-olefin copolymer 0.899 g/cm³; 23.6% 22.3%  7* 0.899 1.0MI @ 2.16 Kg 190° C., melting point 95° C. AMPACET 10090 Slipmasterbatch available from Ampacet 1.0% 1.0%  7* 0.92 (S) Corp.containing LDPE AMPACET 10063 Antiblock masterbatch available from 0.4%0.4%  7* 1.05 (AB) Ampacet Corp. containing polyethylene Total 100.0%100.0% *layer 7 is a 3-component blend, layer 7 is the heat seal layer(or seal layer)

Four panels made from the flexible multilayer film in Table 1 are heatsealed together under the heat seal conditions provided in Table 2(below) to produce flexible containers. The flexible containers arefabricated by KRW Machinery Inc (Weaverville, N.C.). All heat seals inthe flexible containers are made with one strike.

Tables 2A-2B. Heat Seal Conditions for Multilayer Films

TABLE 2A Web Sandwich of 0.6 mm, 4 ply, 150 μm panels Seal Bar PlatenOverseal Temper- Pres- Dwell protrusion ature, sure, Time, height, SealBar Seals ° C. J/cm² sec mm Dimensions Periph- 143 258 0.75 0 10 mm ×eral perimeter for 3.875 L 15 mm × perimeter for 20 L Overseal 182 2580.75 0.30 3.2 mm × 25.4 mm (overseal bar, centered about the apex point,W = 3.5 mm)

TABLE 2B Web Sandwich of 1.0 mm, 4 ply, 250 μm panels Seal Bar PlatenOverseal Temper- Pres- Dwell protrusion ature, sure, Time, height, SealBar Seals ° C. bar sec mm Dimensions Periph- 174 7.4 3.6 0 10 mm × eralperimeter for 3.875 L 15 mm × perimeter for 20 L Overseal 185 7.4 3.60.5 3.2 mm × 25.4 mm (overseal bar, centered about the apex point, W =3.5 mm)

2. Fitment Sealed to Neck Using Expandable Mandrel

Fitments with different base diameters and different base wallthicknesses are inserted into the neck for respective flexiblecontainers. The fitments are made from the same high densitypolyethylene (HDPE). The dimensions and surface texture of the base foreach fitment are provided in Table 3 below.

TABLE 3 Fitment properties Base Base Wall Fitment Diameter, Thickness,outer surface Fitment (d) mm (WT) mm d/WT texture HDPE 1 41 1.6 25.6Ribbed HDPE 2 41 0.75 54.7 Ribbed HDPE 3 110 1.27 86.7 Smooth HDPE 4 1100.5 220 Smooth HDPE 5 110 0.2 550 Smooth INFUSE ™ 9817 41 1.6 25.6Ribbed

The fitments are washed thoroughly in denatured alcohol and allowed todry to prepare surfaces prior to heat sealing to the neck of theflexible container.

Two mandrels are used to heat seal fitments to the flexible containers.A 38 mm diameter mandrel is used for the 3.875 L flexible containers. A110 mm diameter mandrel is used for the 20 L flexible containers. Eachmandrel includes an expandable collar. Each expandable collar is made ofShore A 30+/−5 durometer FDA approved silicone rubber. Applicantdiscovered that silicone rubber is advantageous because of its heatstability, softness and durability.

Properties for the expandable collars are provided in Table 4 below.

TABLE 4 Expandable Collar Properties 38 mm mandrel for 110 mm mandrelfor Expandable 3.875 L flexible 20 L flexible Collar propertiescontainer container Center hole diameter (mm) 6.35 44.5 Relaxed diameter(mm) 29.4 97.1 Radially expanded 44.6 (at 150% 118.3 (at 122% diameter(mm) expansion, 110 psi) expansion, 75 psi)

For the 3.875 L flexible containers, opposing seal bars each with alength of 41 mm are used. The seal width for each opposing seal bar is10.2 mm. The seal bar area for each 41 mm seal bar is 0.0004907 m².

For the 20 L flexible containers, opposing seals bars each with a lengthof 110 mm are used. The seal width for each opposing seal bar is 15.2mm. The seal bar area for each of the 110 mm seal bars is 0.00179 m².

The base of the fitment is heat sealed to the neck of the flexiblecontainer using a mandrel with an expandable collar as set forth incopending case, U.S. Ser. No. 62/146,002, filed on 10 Apr. 2015, theentire contents of which are incorporated by reference herein. The heatseal conditions for the fitment seal are provided in Table 5 below.Table 5 also provides fitment seal integrity data—(i) burst test dataand (ii) hang test data for the fitment seal. In Table 5, “E” denotesinventive example, “CE” denotes comparative sample, and “NS” denotes notsampled.

3. Tests

Burst Test Procedure

Process:

-   -   1.) All flexible containers are numbered/tagged with testing        number, identifying film #, and production set points (if        necessary).    -   2.) All flexible containers are pre-inflated via manual        inflation or compressed air.    -   3.) Caps are applied tightly.    -   4.) Flexible containers are placed inside the vacuum pressure        chamber and lid is closed.    -   5.) Vacuum pressure is applied via vacuum pump. Pressure should        be applied slowly as flexible container continues to inflate.    -   6.) Units of vacuum are recorded in (inHg). Exceptional results        are 18 (inHG) held for 60 seconds. Passing is 12 (inHg).    -   7.) Any weak areas of seal will be exposed as leaks during the        testing time period. Bubbles should be looked for and can        indicate a weak area of the flexible container.    -   8.) The flexible container is filled completely with air and the        closure on the fitment is tightened. Then, the flexible        container is completely submerged in a water bath. The chamber        over the water is then evacuated to create a vacuum. A “pass”        score for the burst test is when there are no bubbles visually        observed in the water bath after 30 seconds at 40 kilopascals of        vacuum.

Gravity Hang Test Procedure

Process:

-   -   1.) All flexible containers are numbered/tagged with testing        number, identifying film #, and production set points (if        necessary).    -   2.) All flexible containers are filled with room temp water to        recommended fill height.    -   3.) 3 drops of Methylene Blue die and 3 drops of surfactant        (soap) are added to each flexible container and agitated.    -   4.) Closures are applied tightly to the fitment.    -   5.) Flexible containers are then hung both neck side down and        neck side up to test the strength of both the neck seal and the        caulk seal areas.    -   6.) Flexible containers are left hanging for 48 hours.    -   7.) Any weak areas of seal will be exposed as leaks during the        testing time period.    -   8.) A “pass” score for the hang test is hanging the flexible        container for 48 hours without a leak detected. Leaks are        detected by visual identification of white paper below the        flexible container to show any drops that have fallen. The water        solution added to the flexible container contains a blue        vegetable dye for aiding visual detection of the leak. The water        solution also contains a drop or two of soap (Dawn dish soap)        where the soap surfactant helps allow water to penetrate any        gaps in seal that might be present.

TABLE 5 Permanent Seal deformation Base Wall Fitment Film Temper- SealSeal Expandable of fitment Exam- Diameter, Thickness, outer thickness,ature, pressure, time, Collar, during Burst Hang ple Fitment (d) mm (WT)mm d/WT surface μm ° C. bar sec Expansion sealing Test Test CE1 HDPE1 411.65 24.8 Ribbed 150 177 2 5.5 0% No Fail — 177 2 6 0% No Pass Pass 1772.2 NS 0% Yes — — 177 4.9 NS 0% Yes — — HDPE1 41 1.65 24.8 Ribbed HDPE1177 4.9 2 150% No Fail — E1 HDPE1 41 1.65 24.8 Ribbed HDPE1 177 4.9 2.5150% No Pass Pass CE2 HDPE2 41 0.75 54.7 Ribbed 150 177 2 5 0% No Fail177 2 6 0% Yes — — 177 2.2 NS 0% Yes — — 177 4.9 NS 0% Yes — — HDPE2 410.75 54.7 Ribbed 150 177 4.9 2 150% No Fail — E2 HDPE2 41 0.75 54.7Ribbed 150 177 4.9 2.5 150% No Pass Pass CE3 HDPE3 110 1.27 86.7 Smooth250 177 1.3 10 0% No Pass Fail 177 1.3 20 0% No Pass Pass E3 HDPE3 1101.27 86.7 Smooth 250 177 1.3 7 116% No Pass Pass CE4 HDPE4 110 0.5 220Smooth 250 149 1.3 NS 0% No Fail — E4 HDPE4 110 0.5 220 Smooth 250 1491.3 10 116% No Pass Pass CE5 HDPE4 110 0.5 220 Smooth 150 149 1.3 NS 0%No Fail — E5 HDPE4 110 0.5 220 Smooth 150 149 1.3 6 116% No Pass PassCE6 HDPE5 110 0.2 550 Smooth 250 149 1.3 NS 0% No Fail — E6 HDPE5 1100.2 550 Smooth 250 149 1.3 9 116% No Pass Pass E7 HDPE5 110 0.2 550Smooth 150 149 1.3 5 122% No Pass Pass CE7 INFUSE ™ 41 1.6 25.6 Ribbed150 177 4.9 NS 0% No Fail — 9817 INFUSE ™ 41 1.6 25.6 Ribbed 150 177 4.93 150% No Fail — 9817 E8 INFUSE ™ 41 1.6 25.6 Ribbed 150 177 4.9 4 150%No Pass Pass 9817

Applicant discovered that utilization of the mandrel with expandablecollar during the fitment heat seal procedure advantageously enables theuse of fitment base having thin-wall structure. Thin-wall orthin-walling is the reduction of the wall thickness for the fitmentbase. Examples E2, E4, E5, E6, and E7, show that fitments with d/WTratio from 35, or 54.7 (thin-wall), or 86.7 to 220 (thin-wall), or 550(thin-wall) (i) can be successfully heat sealed to the neck of theflexible container, (ii) avoid deformation, (iii) pass the burst test,(iv) pass the hang test, and (v) simultaneously fulfill each of (i)through (iv).

Utilization of the mandrel with expandable collar during the fitmentheat seal procedure also enables the use of polymeric materials notpreviously suitable for fitment applications. The mandrel withexpandable collar supports the fitment during the sealing, and preventsdeformation. Thus, the mandrel with expandable collar enables polymericmaterials previously either too soft or too rigid (cracking) to now beused as fitments alone or thin-walled. Example E8 (with expandablecollar) shows that INFUSE 9817, an elastomer, can be used as a suitablefitment material. Whereas comparative sample CE7 (INFUSE 9817) sealedwithout the expandable collar fails the burst test. Example E8 (i) issuccessfully heat sealed to the neck of the flexible container, (ii)avoids deformation, (iii) passes the burst test, (iv) pass the hangtest, and (v) simultaneously fulfill each of (i) through (iv).

Utilization of the mandrel with expandable collar during the fitmentheat seal procedure also enables shorter seal times without degradingseal strength. Example E3 (with expandable collar) yields an acceptablefitment seal (passing burst test and hang test) with 7 seconds seal timewhile comparative sample CE3 (no expandable collar) requires 20 secondsto produce an acceptable fitment seal.

The mandrel with expandable collar enables greater seal pressure to beapplied to the fitment. Example E2 (with expandable collar) yields anacceptable fitment seal (passing burst test and hang test) at 4.9 sealbar pressure, whereas comparative sample CE2 at 4.9 seal bar pressure ispermanently deformed.

Applicant unexpectedly found that the mandrel with expandable collarenables the production of a four-panel flexible container with ahermetically sealed fitment wherein the base wall thickness is from 0.2mm, or 0.5 mm to 0.75 mm (thin-wall base).

It is specifically intended that the present disclosure not be limitedto the embodiments and illustrations contained herein, but includemodified forms of those embodiments including portions of theembodiments and combinations of elements of different embodiments ascome with the scope of the following claims.

1. A flexible container comprising: (A) four panels, each panelcomprising a flexible multilayer film comprising a polymeric material,the four panels forming (i) a body, and (ii) a neck; (B) a fitmentcomprising a top portion and a base, the fitment composed of a polymericmaterial, the base sealed in the neck; and (C) the base has across-sectional shape with a uniform diameter (d), the base has a wallthickness (WT), wherein the d/WT ratio (in mm) is from 35 to
 800. 2. Theflexible container of claim 1 wherein the cross-sectional shape of thebase is selected from the group consisting of circle and regularpolygon.
 3. The flexible container of claim 1 wherein thecross-sectional shape of the base is a circle.
 4. The flexible containerof claim 1 wherein the cross-sectional shape of the base is a square. 5.The flexible container of claim 1 wherein the diameter of the base isgreater than the diameter of the top portion.
 6. The flexible containerof claim 1 wherein the diameter (d) is from 10 mm to 120 mm.
 7. Theflexible container of claim 1 wherein the wall thickness (WT) is from0.15 mm to 0.75 mm.
 8. The flexible container of claim 1 wherein thepolymeric material for the fitment is selected from the group consistingof propylene-based polymer, ethylene-based polymer, polyamide, cyclicolefin copolymer, polyester, copolyester, cellulose ester, andcombinations thereof.
 9. The flexible container of claim 1 whereinpolymeric material for the fitment is an ethylene-based polymer having a2% secant flexural modulus from 10 MPa a to less than 200 MPa.
 10. Theflexible container of claim 1 wherein the flexible multilayer film has aclarity greater than 80% and haze less than 20% (at 0.5 mm thickness).11. The flexible container of claim 1 wherein the polymeric material forthe fitment has clarity greater than 80% and haze less than 20% (at 0.5mm thickness).
 12. The flexible container of claim 1 comprising ahermetic seal between the neck and the base.